Thermal Clip Attachment Apparatus for Masonry Anchors and Methods Thereof

ABSTRACT

A thermal clip attachment apparatus and methods for using the thermal clip attachment with a masonry veneer anchor system are disclosed. The thermal clip attachment may be a composite piece that attaches to the part of a stud that protrudes from an inner structural supportive wall after the stud is advanced into the wall. The thermal clip attachment serves as a thermal break between the stud and an outer masonry veneer wall. Further, the thermal clip attachment also serves as an attachment point for a wire tie, which allows a positive lateral load connection to be established between the outer masonry veneer wall and the inner structural supportive wall.

PRIORITY STATEMENT

This application claims the benefit of U.S. Provisional Application No.61/602,178, filed Feb. 23, 2012.

FIELD OF THE INVENTION

The present invention relates generally to a masonry veneer anchorsystem and, more specifically, to a thermal clip attachment for amasonry veneer anchor system.

BACKGROUND OF THE INVENTION

Masonry veneer anchor systems are used to establish a positive lateralload connection between an outer masonry veneer wall and an innerstructural supportive wall. Typically, one end portion of aself-drilling, self-tapping stud is screwed into a stud holder formed bya generally cylindrical barrel having an integral, tongue-like drivinghead on one end thereof. An eye for a wire tie is formed through thedriving head while cutting elements are formed on the end of the barrelopposite the head.

Oftentimes the stud is adapted to be driven by a power-rotated socket,which is sized and shaped to telescope into driving engagement with thedriving head of the stud holder. When the stud is driven, it drillsthrough a layer of insulation on a supportive wall and then drills andtaps into the supportive wall itself. During driving of the stud, thecutting elements on the barrel of the stud holder drill a counterbore inthe insulation to receive the barrel so as to cause the barrel to seatitself and the stud tightly in the insulation and the supportive wall.

After the stud and the stud holder have been driven, one portion of awire tie is threaded through the eye of the driving head while anotherportion of the wire is embedded in the mortar or other cement-likematerial of a masonry veneer wall disposed alongside the supportivewall. The wire tie provides a positive lateral load connection betweenthe masonry veneer wall and the supportive wall.

Some variants of masonry veneer anchor systems utilize wing nutattachments that are mounted on the stud holder. Wing nut attachmentscan provide more secure attachment points for the wire tie and can,depending on a material composition such as plastic, create a thermalbreak between the stud holder and the wire tie. The thermal break canreduce the amount of thermal energy transfer between the outer masonryveneer wall and the internal supportive wall. But such wing nutattachments are mounted to the stud holder before the stud holder isdriven into the insulation and supportive wall. One disadvantage of thecurrent masonry anchor design is that the arrangement can causeabrasions if an installer's hand slips off of the drive mechanism andmakes contact with the spinning wing nut attachment as the stud holderis driven into place. Further, some wing nut attachments may require thestud holder to have external threads that mate with internal threads ofthe wing nut. These thread assemblies add unnecessary costs to both thestud holder and the wing nut. Also, in some installments, there is adelay between the time the masonry anchors are installed in the internalsupportive wall and the time that the outer veneer wall is built. Duringthis delay, the wing nut attachment may be subjected to the elements,including the sun, for a length of time. Certain plastic material can bedamaged by the radiation given off by the sun.

Thus, there is a long felt need in the field of masonry veneer anchorsystems for a cost-effective thermal clip attachment that can serve as athermal break, that attaches to the stud holder after the stud holder isdriven into the insulation and supportive wall, and that works withexisting types of stud holders.

SUMMARY OF THE INVENTION

The present invention aims to provide a new and improved masonry veneeranchor system and, more specifically, a thermal clip attachment for theanchor system. The masonry veneer anchor system, which is intended toestablish a positive lateral load connection between an outer masonryveneer wall and an inner structural supportive wall, may generallyinclude a stud, a thermal clip attachment, and a wire tie.

The stud may include a stud driver and holder, a threaded stud,combinations thereof, or an integral one-piece stud. The stud may besized, threaded, shaped, and formed so that it may be advanced through alayer of insulation adjacent to the interior structural supportive walland through, or at least into, the interior structural supportive wall.The stud may also include a part that is intended to receive the thermalclip attachment. When advancing the stud into the layer of insulationand the interior structural supportive wall, the part that receives thethermal clip attachment may be left to protrude from the layer ofinsulation.

The thermal clip attachment may be a composite piece that attaches tothe part of the stud that protrudes from the layer of insulation.Moreover, the thermal clip attachment may be made of a non-conductingmaterial to serve as a thermal break between the stud and the outermasonry veneer wall. The thermal clip attachment may have holes or otherpoints of attachment for connection to extensions of a wire tie, whichis used to secure the stud to the outer masonry veneer wall.

The thermal clip attachment can have many embodiments. One advantage ofthe merely exemplary embodiments described herein is that the thermalclip attachment can be used with existing types of studs.

In one embodiment, the thermal clip attachment has a cavity forselectively receiving an outer driving head of the stud. The thermalclip attachment may also include a resilient prong having a lip, withthe resilient prong generally disposed throughout a portion of thecavity. When the cavity of the thermal clip attachment is forced ontothe outer driving head of the stud, the prong is temporarily displaceduntil the lip of the prong catches an eye, or opening, in the outerdriving head of the stud. At that point, the prong snaps back into placeand secures the outer driving head within the cavity.

In another embodiment, the thermal clip attachment includes first andsecond portions. The first and second portions may form a cavity forreceiving the part of the stud that protrudes from the layer ofinsulation. Further, the first and second portions may be rotatablerelative to one another, and the first and second portions may beselectively fastened to one another. Thus, the first and second portionsmay be placed in an open position to receive a part of the stud. Oncethe part of the stud is secured within the cavity the first and secondportions are rotated back to a closed position and fastened to oneanother. One exemplary way to secure the part of the stud within thecavity is to place an opening of the part of the stud around a peg,which is fixed within the cavity as an integral part of the thermal clipattachment. After the thermal clip attachment is affixed to the stud,the wire tie may be connected to both the thermal clip attachment andthe outer masonry wall.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred embodiments of the invention will be described inconjunction with the appended drawings, which illustrate and do notlimit the invention, where like designations denote like elements, andin which:

FIG. 1 is a sectional view of a masonry veneer wall and a supportivewall having a partial anchoring system.

FIG. 2 is an end view of an outer driving head of a stud driver andholder that is used in the anchoring system.

FIG. 3 is a fragmentary cross-sectional view of the outer driving headtaken substantially along the line 3-3 of FIG. 2.

FIG. 4 is an end view of a power-rotated driving tool having a socketthat is contoured to receive the outer driving head in FIG. 2.

FIG. 5 is a fragmentary cross-sectional view of the partial anchoringsystem taken substantially along line 2-2 of FIG. 1.

FIG. 6 is a fragmentary cross-sectional view of a stud driver and holderand a threaded stud taken substantially along line 4-4 of FIG. 5.

FIG. 7 is a side view of another embodiment of a stud driver and holderfor use in an anchoring system.

FIG. 8 is a side view of still another embodiment of a stud driver andholder for use in an anchoring system.

FIGS. 9A and 9B show, respectively, side and bottom views of a thermalclip attachment that can be affixed to an outer driving head of a studdriver and holder in accordance with the present invention.

FIGS. 9C through 9G show perspective views of a thermal clip attachmentthat is similar to that shown in FIGS. 9A and 9B. FIG. 9G shows athermal clip attachment after insertion of the stud driver and holder.

FIGS. 10A and 10B show, respectively, front and back views of thethermal clip attachment of FIGS. 9A-9B affixed to an outer driving headof a stud driver and holder in accordance with the present invention.

FIG. 11 provides a perspective view of a wire tie that can be used toconnect the thermal clip attachment of FIGS. 9A, 9B, 10A, and 10B withan outer masonry wall in accordance with the present invention.

FIG. 12A shows a cross-sectional view taken substantially along the line5-5 in FIG. 12B of another embodiment of a thermal clip attachment in aclosed position in accordance with the present invention.

FIG. 12B shows a side view of the thermal clip attachment of FIG. 12A inaccordance with the present invention.

FIG. 13A shows a cross-sectional view similar to that in FIG. 12A, in anopen position in accordance with the present invention.

FIG. 13B shows a side view of the thermal clip attachment of FIGS. 12A,12B, and 13A in a closed position, with an outer driving head of a studdriver and holder (shown in hidden) clamped within the thermal clipattachment in accordance with the present invention.

FIG. 14 shows a cross-sectional view of the thermal clip attachment ofFIGS. 12A, 12B, 13A, and 13B, with extensions of a wire tie insertedthrough holes of the thermal clip attachment in accordance with thepresent invention.

FIG. 15A shows a top view of an alternative embodiment of a thermal clipattachment in a closed position in accordance with the presentinvention.

FIG. 15B shows a side view of the thermal clip attachment of FIG. 15A inaccordance with the present invention.

FIG. 16A shows a top view of the thermal clip attachment of FIGS. 15Aand 15B, in an open position in accordance with the present invention.

FIG. 16B shows a side view of the thermal clip attachment of FIGS. 15A,15B, and 16A in an open position, with an outer driving head of a studdriver and holder (shown in hidden) positioned near one portion of thethermal clip attachment in accordance with the present invention.

FIG. 17A provides a perspective view of an alternative embodiment of athermal clip attachment having first and second portions that areslidably engageable in accordance with the present invention.

FIG. 17B provides a perspective view of the thermal clip attachment ofFIG. 17A, with the first and second portions being slidably engaged inaccordance with the present invention.

FIG. 18A provides a perspective view of a stud driver and holder towhich the thermal clip attachment of FIGS. 17A and 17B may be affixed inaccordance with the present invention.

FIG. 18B provides a perspective view of the stud driver and holder ofFIG. 18A with the thermal clip attachment of FIGS. 17A and 17B affixedthereto in accordance with the present invention.

FIG. 19A provides a perspective view of an alternative embodiment of athermal clip attachment having first and second portions that areengageable, in an open position in accordance with the presentinvention.

FIG. 19B provides a perspective view of the thermal clip attachment ofFIG. 19A, with the first and second portions being engaged in accordancewith the present invention.

FIG. 20 provides a perspective view of the stud driver and holder ofFIG. 8 with the thermal clip attachment of FIGS. 19A and 19B positionedthereto prior to engagement in accordance with the present invention.

FIG. 21 provides a perspective view of the stud driver and holder withthe thermal clip attachment of FIG. 20 engaged with a wire tie attachedin accordance with the present invention.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

Before proceeding to a description of the thermal clip attachmentapparatus and methods of using the same, it is helpful to discuss someof the other components used in a system for establishing a positivelateral load connection between an outer masonry veneer wall 10 and aninner structural supportive wall 12, such as the partial masonryanchoring system 14 shown in FIG. 1. Noticeably absent from FIG. 1 are awire tie and the thermal clip attachment, which are described below withreference to FIGS. 9 through 19.

The outer masonry veneer wall 10 can be formed, for example, from bricksthat are joined to one another by mortar or other cementitious material.In some embodiments, the inner structural supportive wall 12 may beformed by an inner sheet of thin steel 16 and by an outer layer 18 ofhard, rigid, fire-resistant insulation, such as that sold byWeyerhaeuser under the trademark ULTRABOARD, for example.

In general, the masonry anchoring system 14 may comprise four basiccomponents, namely, a threaded stud 20, a stud driver and holder 22, athermal clip attachment (not shown), and a wire tie (not shown). In theembodiment shown in FIG. 1, the threaded stud 20 may include anelongated metal shank 24 formed with a self-drilling tip 26 and formedwith a self-tapping machine thread 28. When the threaded stud 20 isdriven by being rotated and advanced axially, the self-drilling tip 26drills through the insulation 18 and the inner sheet of thin steel 16and then the self-tapping machine thread 28 screws itself into the innersheet of thin steel 16.

The stud driver and holder 22 may generally include an elongatedcylindrical barrel 30 formed integrally with an outer driving head 32,which may be in the form of a flat, axially projecting tongue ofgenerally rectangular shape and generally rectangular cross-section. Thestud driver and holder 22 may be, for example, die cast from azinc-aluminum alloy or stainless steel.

An axially extending threaded hole 34 may be formed in the inner endportion of the barrel 30 of the stud driver and holder 22. The axiallyextending threaded hole 34 may be sized to receive the outer end portionof the self-tapping machine thread 28 of the threaded stud 20. Thethreaded stud 20 may be screwed snugly into the elongated cylindricalbarrel 30 by hand before the threaded stud 20 and stud driver and holder22 are driven. As described below, when the threaded stud 20 is driven,the elongated cylindrical barrel 30 drills through the insulation 18 andforms an enlarged counterbore 36, which receives the elongatedcylindrical barrel 30 in the finally installed position of the threadedstud 20.

With continued primary reference to FIG. 1, an enlarged,radially-extending, circular flange 38 may be formed as an integral partof the stud driver and holder 22. FIG. 2, however, provides an end viewof the circular flange 38 and the outer driving head 32, while FIG. 3provides a fragmentary cross-sectional view taken substantially alongthe line 3-3 of FIG. 2. The circular flange 38, which need notnecessarily be circular, may be located between the outer end of theelongated cylindrical barrel 30 and the inner end of the outer drivinghead 32. The circular flange 38 may work with a pair of gussets 40 thatincrease the strength of the outer driving head 32 when torque isapplied to the outer driving head 32 during installation of the threadedstud 20 and the stud driver and holder 22. The pair of gussets 40 may beformed integrally with opposite sides of the outer driving head 32midway along the length of an inner long edge 42 of an eye 44 of theouter driving head 32 and at junctions between the outer driving head 32and the circular flange 38. The gussets 40 may be generally triangularin cross-section and serve to reinforce the joint between the outerdriving head 32 and the circular flange 38 so as to prevent the outerdriving head 32 from shearing away from the circular flange 38 when hightorque is applied to the outer driving head 32.

Driving of the threaded stud 20 and the stud driver and holder 22 may beeffected by an automatic screw gun (not shown) having a power-rotateddriving tool 46, as shown in a bottom view in FIG. 4. The power-rotateddriving tool 46 may be formed with a socket 48 that is shaped to coupledrivingly with the outer driving head 32 of the stud driver and holder22. The socket 48 of the driving tool 46 may be formed with arcuatenotches 50, which can accommodate the gussets 40 when the socket 48 istelescoped into driving relation with the outer driving head 32. Thesocket 48 generally may be shaped as an elongated slot formed in thedriving tool 46 and opening out of a flat driving face 52 thereof. Thecross-sectional size and shape of the socket 48 may correspondsubstantially to the cross-sectional size and shape of the outer drivinghead 32.

As the stud driver and holder 22 is driven into place, the outer side ofthe circular flange 38 may squarely engage the flat driving face 52 ofthe driving tool 46 and serve to stabilize the stud driver and holder 22in the socket 48 as the stud driver and holder 22 is rotated andadvanced axially. When the threaded stud 20 is fully driven, the innerface of the circular flange 38 may seat tightly against an outer side ofthe insulation 18 and thus may serve as a washer to close off and sealthe enlarged counterbore 36 in the insulation 18. For the circularflange 38 to effectively close off the enlarged counterbore 36, thediameter of the circular flange 38 may be significantly greater than thediameter of the elongated cylindrical barrel 30. The elongatedcylindrical barrel 30 of one exemplary stud holder and driver 22 mayhave a diameter of about ⅜″ while the flange has a diameter of about ¾″.

In the alternative, a separate washer (not shown) may be mounted aroundthe stud holder and driver 22 beneath the circular flange 38. Theseparate washer may, in some embodiments, be formed by using adhesive tomount a composite layer to a bottom of a metallic layer. Once mounted onthe stud holder and driver 22, the metallic layer may be closest to thecircular flange 38, while the composite layer could mate with a surfaceof the insulation 18 surrounding the enlarged counterbore 36. Theseparate washer may be advantageous in that the composite layer may bemore suitable for mating with the insulation 18. For example, thecomposite layer may be softer and hence more gentile on the insulation18 and may also form a more-airtight seal with the insulation 18, ascompared to the circular flange 38 or the metallic layer of the separatewasher. Moreover, the metallic layer could be slightly resilient andhave inwards concavity, that is, concavity towards the insulation 18. Byslightly deforming the metallic layer during installation, the metalliclayer would assist in both maintaining the composite layer against theinsulation 18 and maintaining a degree of tension in the joint.

To enable the elongated cylindrical barrel 30 to drill the enlargedcounterbore 36 effectively through insulation 18, which is both hard andrigid, and through insulation 54 (see, e.g., FIG. 7), which is soft andcompressible, the inner end portion of the elongated cylindrical barrel30 of the stud driver and holder 22 may be formed with cutting elements56, as shown in FIG. 1. Alternative views of the cutting elements 56 canbe seen in FIGS. 5 and 6. FIG. 5 is a fragmentary cross-sectional viewalong the line 2-2 of the partial anchor system shown in FIG. 1, andFIG. 6 is a fragmentary cross-sectional view taken substantially alongthe line 4-4 of FIG. 5.

In one embodiment, shown best in FIG. 5, there may be four cuttingelements 56 in the form of cutting edges that are spaced angularlyaround and extending axially along the inner end portion of theelongated cylindrical barrel 30, parallel to an axis thereof. Thecutting edges may be defined by the outer leading edges of fourangularly spaced ribs 58 and lie on a cutting circle having the samediameter as the outer diameter of the elongated cylindrical barrel 30.Tips 60 of the ribs may be inclined at a negative axial rake angle ofabout 10 degrees, as shown best in FIGS. 1 and 6.

FIG. 6 also shows relieved flutes 62, which may be formed between theangularly spaced ribs 58 and extend axially along the elongatedcylindrical barrel 30 between the cutting elements 56 of the angularlyspaced ribs 58. The bottoms of the relieved flutes 62 may be convexlyarcuate and lie along a common circle having a diameter less than theouter diameter of the barrel. The relieved flutes 62 may define pocketsthat store the material of the insulation when the enlarged counterboreis drilled through the insulation.

As a result of the axially extending and angularly spaced cuttingelements 56, the elongated cylindrical barrel 30 may be capable ofdrilling through very hard insulation 18 such as ULTRABOARD. Inaddition, the barrel is capable of drilling a clean enlarged counterbore36 through soft and compressible insulation 54, such as the polystyreneinsulation shown in FIG. 7, for example, without crushing or packing thematerial into the enlarged counterbore 36. As the soft material is cutaway, it is stored in the pockets defined by the relieved flutes 62 anddoes not interfere with the action of the cutting elements 56penetrating the material.

As one skilled in the art will appreciate, the present invention may beused with a wide variety of stud holders. For example, anotherembodiment of a stud driver and holder 64 is shown in FIG. 7. The studdriver and holder 64 in FIG. 7 may be similar to the stud driver andholder 22, except that an elongated cylindrical barrel 66 of the studdriver and holder 64 of FIG. 7 may be longer to enable it to penetratesubstantially the entire thickness of the relatively thick polystyreneinsulation 54. In FIG. 7, the insulation 54 is shown as attached to acomparatively thick concrete wall 66 and thus the inner end portion of athreaded stud 68 is formed with a masonry thread 70 while the outer endportion of the threaded stud 68 is formed with a machine thread in thesame manner as the threaded stud 20. The threaded stud 68 may be idealfor drilling through concrete or a concrete masonry unit (CMU), forexample. Further, a flange 72 may be formed between the two threads ofthe threaded stud 68 and engage the outer side of the concrete wallthick concrete wall 66 and the inner end of the stud driver and holder64 when the stud driver and holder 64 is fully tightened.

Still another embodiment of an exemplary stud holder that is compatiblewith the present invention is shown in FIG. 8. A threaded stud 74 shownin FIG. 8 may be a stud of the type sold by Heckmann Building Products,Inc. under the trademark POS-I-TIE®and may be used with the stud driverand holder 22 or 64 interchangeably. The threaded stud 74, which mayinvolve a structural screw, is particularly designed to drill and tapthrough thick steel and is formed with an intermediate hexagonal collar76. The intermediate hexagonal collar 76 may be used to index the blankfrom which the stud is formed in a proper angular orientation duringformation of the drilling tip and also may be engaged and turned by awrench if it should be necessary to remove the stud from the supportivewall.

Referring now to FIGS. 9A and 9B, once the threaded stud and stud driverand holder have been driven into place, a thermal clip attachment 90 maybe affixed to the outer driving head or other attachment part of thestud driver and holder. FIGS. 9A and 9B show, respectively, side andbottom views of merely one embodiment of the thermal clip attachment 90.In this embodiment, the thermal clip attachment 90 may include a hole 92in each of its outer tabs 94. The holes 92 may receive extensions of awire tie (not shown) that can be connected to the outer masonry veneerwall. The thermal clip attachment 90 may also have a cavity 96 withinwhich a substantial portion of the outer driving head of the stud driverand holder may be selectively disposed. Edges near a bottom opening 97of the cavity 96 may be rounded or graded (not shown) for the ingress ofcomponents into the cavity 96. Further, a prong 98 may extend downwardfrom a top 100 of the thermal clip attachment 90 to occupy a portion ofthe cavity 96, and the prong 98 may be offset laterally within thecavity 96. The top 100 of the thermal clip attachment 90 may be asurface that encloses one side of the cavity 96. Also, the prong 98 mayhave a lip 102 that is sized to catch the eye of the outer driving headof the stud driver and holder 108.

The thermal clip attachment 90 may be formed of a composite material,such as plastic or a plastic resin such as RADEL®, that acts as athermal break between the outer masonry veneer wall and the stud driverand holder. Moreover, the composite material may be selected such thatthe prong 98 is laterally displaceable when the outer driving head ofthe stud driver and holder is forced into the cavity 96. Morespecifically, the prong 98 may have a sloped surface 104 beneath the lip102 that is engaged by the outer driving head when the thermal clipattachment 90 is initially forced onto the stud driver and holder. Inother embodiments, the thermal clip attachment 90 may be formed from ametal, such as a zinc alloy, stainless steel, or the like. Further, thethermal clip attachment 90 may be formed from a combination of thoseplastics and metals described above.

As the outer driving head is forced into the cavity 96, the forcesacting on the sloped surface 104 begin to displace the prong 98partially or completely out of the cavity 96. Once the outer drivinghead is pressed far enough into the cavity 96, the lip 102 of the prong98 passes into and catches the eye of the outer driving head as theprong 98 snaps back into the cavity 96, affixing the outer driving headwithin the cavity 96 of the thermal clip attachment 90.

FIGS. 9C through 9G show the perspective views for a thermal clipattachment 90 that is substantially similar to the embodiment shown inFIGS. 9A through 9B. Similar to FIGS. 9A and 9B, FIGS. 9C through 9Eshow the thermal clip attachment 90 with the holes 92, the outer tabs94, the cavity 96, the prong 98, the top 100 of the thermal clip, thelip 102, and the sloped surface 104 beneath the lip 102. FIG. 9E shows abottom cut away view of the thermal clip attachment 90, with theunderstanding that the bottom of the thermal clip attachment 90 is asolid piece. FIG. 9F is a side cut away view of FIG. 9C, and FIG. 9Gshows the thermal clip attachment 90 with a stud driver and holderinserted into the thermal clip attachment.

FIGS. 10A and 10B provide, respectively, front and back views of athermal clip attachment 90 that has been pressed onto an outer drivinghead 106 of a stud driver and holder 108. It should be noted that thestud driver and holder 108 in FIGS. 10A and 10B have not been driveninto insulation and an inner structural supportive wall. Likewise, theparticular thermal clip attachment 90 shown in FIGS. 10A and 10B had thetop 100 severed from the remainder of the thermal clip attachment 90 forworking purposes. In practice, the top 100 may be formed and keptintegrally with the thermal clip attachment 90. Notwithstanding, theouter driving head 106 in FIGS. 10A and 10B has been pressed up into thecavity 96 of the thermal clip attachment 90. The prong 98 has alreadybeen displaced during the insertion of the outer driving head 106, andthe lip 102 of the prong 98 now rests at least partially within an eyeof the outer driving head 106.

Because many existing stud drivers and holders already have eyes intheir outer driving heads, similar to the eye 44 shown in FIG. 1, thethermal clip attachment 90 is usable with new and existing forms of studdrivers and holders and wire ties, described below. Thus, integration ofthe thermal clip attachment 90 will be seamless.

After the thermal clip attachment is affixed to the outer driving headof the stud driver and holder, a wire tie 110 as shown in FIG. 11 may beattached to the thermal clip attachment. The wire tie 110 may include ahandling portion 112 and extensions 114. An installer of the wire tie110 may grip the wire tie 110 by the handling portion 112. Theextensions 114 may be placed through the holes on the outer tabs of thethermal clip attachment. The wire tie 110 may assist with rotating thethermal clip attachment and outer driving head such that the holes onthe outer tabs of the thermal clip attachment are generally vertical.The extensions 114 may either be inserted upwards or downwards throughthe holes in the thermal clip attachment. Once inserted, the handlingportion 112 of the wire tie 110 may rest along a constituent row ofbricks or stones, for example, which form a portion of an outer masonryveneer wall under construction. Mortar may then be placed along the rowof bricks upon which the handling portion 112 of the wire tie 110 rests.When the mortar sets up, the wire tie 110 forms a positive lateral loadconnection between the masonry veneer wall and the inner supportivewall.

FIGS. 12 through 14 show slightly different views of another embodimentof the thermal clip attachment 90. Specifically, FIG. 12A shows, across-sectional view taken substantially across line 5-5 in FIG. 12B ofthe thermal clip attachment 90 in a closed position. FIG. 12B shows aside view of the thermal clip attachment 90 of FIG. 12A. FIG. 13A showsa cross-sectional view similar to FIG. 12A, except that the thermal clipattachment 90 is in an open position. FIG. 13B shows a side view of thethermal clip attachment 90, again in a closed position, but with thethermal clip attachment 90 clamped onto an outer driving head 120 of astud driver and holder 122 (shown in hidden). FIG. 14 shows stillanother cross-sectional view of the same embodiment, although extensions114 of a wire tie have been inserted through holes 124 of the thermalclip attachment 90.

The thermal clip attachment 90, as shown in FIGS. 12 through 14, mayinclude a recess 126, which allows a first portion 128 of the thermalclip attachment 90 to rotate relative to a second portion 130 of thethermal clip attachment 90. Such rotation allows for the outer drivinghead 120 to be inserted into a cavity 132 in the thermal clip attachment90 when opened. The outer driving head 120 may be affixed within thecavity 132 by arranging an eye 134 of the outer driving head 120 over apeg 136 that is integral with the thermal clip attachment 90. Anotherpeg 138 may be included to further secure the outer driving head 120within the cavity 132. Once the outer driving head 120 is in placewithin the cavity 132, the first portion 128 of the thermal clipattachment 90 may be rotated back towards the second portion 130. Tofasten the first and second portions 128, 130 back to one another, afastener 140, such as a rivet, on the first portion 128 may be insertedthrough a countersink 142 in the second portion 130. The fastener 140may be formed around one of the holes 124 and may include a deformableflange 144. The deformable flange 144 may be squeezed through thecountersink 142 and come to rest in an angled seat 146 of thecountersink 142 in the second portion 130. With the deformable flange144 secured in the angled seat 146 of the countersink 142, the firstportion 128 is prevented from rotating relative to the second portion130. Once the thermal clip attachment 90 is affixed to the stud holderand driver 122, the extensions 114 of a wire tie may be fed through theholes 124 in the thermal clip attachment 90, as shown specifically inFIG. 14.

FIGS. 15 and 16 show still another embodiment of the thermal clipattachment 90. FIG. 15A shows a top view of a closed thermal clipattachment 90, while FIG. 15B shows a side view of the same. Conversely,FIG. 16A shows a top view of the thermal clip attachment 90 of FIGS. 15Aand 15B in an open position, while FIG. 16B shows a side view of thesame. The thermal clip attachment 90 shown here is similar to theembodiment shown in FIGS. 12 through 14, except that the first portion128 rotates about a hinge 148 and has at least one clasp 150 thatselectively engages at least one curved recess 152 in the second portion130 when the two portions 128, 130 are closed. The fastener 140 andother portions of the thermal clip attachment 90 work similarly, if notidentically, to the components described above. Thus, for the sake ofbrevity, the duplicative components of this embodiment are not describedagain in full.

FIGS. 17A and 17B illustrate an alternative embodiment of the thermalclip attachment 90. This embodiment is similar to the others, but forseveral distinct features. For one, the first and second portions 128,130 of the thermal clip attachment 90 may be entirely detachable fromone another. Moreover, the first and second portions 128, 130 may evenbe formed from the same tooling, such that the first and second portions128, 130 both have a retaining feature 154 and a distal end 156. Thefirst and second portions 128, 130 may be slidably engageable with oneanother such that the retaining feature 154 of each portion 128, 130 canbe placed about the distal end 156 of each portion 128, 130. Althoughthe first and second portions 128, 130 may be slid apart, the retainingfeatures 154 prevent the first and second portions 128, 130 from pullingtangentially away from one another. This embodiment is further differentin that the thermal clip attachment 90, when intact, may have a chamber158, such as an octagonal- or hexagonal-shaped chamber, for example, forreceiving a portion of a stud driver and holder. Thus, the thermal clipattachment 90 of FIGS. 17A and 17B may be used with stud drivers andholders that do not have an outer driving head like that shown in FIG.1.

As shown in FIGS. 18A and 18B, the thermal clip attachment 90 of FIGS.17A and 17B may be attached to a stud driver and holder 160 with asegment 162 having a polygonal cross section that corresponds to thesize and shape of the chamber 158 of the thermal clip attachment 90. Thesegment 162 may be along the shank or barrel of the stud driver andholder 160, for example. In practice, then, once the stud driver andholder 160 is driven into place such that only the segment 162 and,optionally, a washer on the stud driver and holder 160 are protrudingfrom the insulation, the first portion 128 may be placed around thesegment 162. The second portion 130 may be slid onto the first portion130 such that the retaining features 154 and distal ends 156 mate withone another. To further secure the portions 128, 130 to one another andabout the stud driver and holder 160, extensions of a wire tie (notshown) may be slid into the holes 124 of the thermal clip attachment 90.At this point, the thermal clip attachment 90 is affixed together andabout the stud driver and holder 160. The chamber 158 of the thermalclip attachment 90 can mate with the segment 162 of the stud driver andholder 160 such that the thermal clip attachment 90 is not rotatableabout the segment 162 and hence the stud driver and holder 160. Further,the thermal clip attachment 90 is secured between a head 164 of the studdriver and holder 160 and either the insulation (not shown) or a washer(not shown) contacting the insulation.

FIGS. 19A and 19B show still another embodiment of the thermal clipattachment 90. FIG. 19A shows a perspective view of the thermal clipattachment 90 in an open position, while FIG. 19B shows a perspectiveview of a closed thermal clip attachment 90.

Similar to the thermal clip attachment 90 in FIGS. 16A and 16B, thethermal clip attachment 90 shown here has a first portion 170 and asecond portion 172. The first portion 170 rotates about at least onehinge 174, and in the example shown, three hinges. The first portion 170has at least one tab 176 that selectively engages at least one cavity178 located on the second portion 172. The cavity 178 may be apass-through 180 as shown, although such a complete pass-through 180 isnot necessary. When the two portions 170, 172 are closed about the hinge174, the tab 176 will engage and be secured in the cavity 178 therebycreating the closed thermal clip attachment 90 shown in FIG. 19B. Thetab 176 and cavity 178 of the thermal clip attachment 90 work similarlyto the components of the other thermal clip attachment embodimentsdescribed above, and duplicative components of this embodiment are notdescribed again in detail.

As shown in FIG. 20, the first portion 170 of the thermal clipattachment 90 allows for the outer driving head 120 of a stud driver andholder 122 to be affixed in the thermal clip attachment 90 prior toclosing. The outer driving head 120 may be affixed by arranging an eye134 of the outer driving head 120 into a cavity 182 and over a peg 184that is integral with the first portion 170 of the thermal clipattachment 90. Once the outer driving head 120 is in place within thecavity 182 and over the peg 184, the second portion 172 of the thermalclip attachment 90 may be rotated towards the first portion 170 aboutthe hinges 174. A recess 186 integral in the second portion 172 isconfigured to receive and accept the peg 184 and further lock in thedriving head 120 upon closing. However, the recess 186 may not benecessary to properly contain and secure the driving head 120.

To fasten the first and second portions 170, 172, tab 176 on the firstportion 170 engages the cavity 178 on the second portion 172 and locksthe two portions 170, 172 together, thereby locking the driving head 120in place. With the tab 176 secured in the cavity 178, the first portion170 is prevented from rotating back away from the second portion 172.

Both the first portion 170 and the second portion 172 contain holes 188that line up upon closing the thermal clip attachment 90. As such, oncethe thermal clip attachment 90 is closed as shown in FIG. 19B, andaffixed to the stud holder and driver 120, the extensions 114 of a wiretie 110, such as that shown in FIG. 11, may be fed through the holes 188in the thermal clip attachment 90, as shown specifically in FIG. 21.

It will be appreciated that in addition to the structure of the anchorsystem and thermal clip attachment described herein, another aspect ofthe present disclosure is a method for installing masonry anchorsystems. It will be further appreciated that the methodology andconstituent steps thereof performed and carried out by an installer ofthe anchor system, and described in great detail above, apply to thisaspect of the disclosure with equal force. Therefore, the description ofthe methodology performed or carried out by an installer using theanchor system and/or thermal clip attachment set forth above will not berepeated in its entirety. Rather, several exemplary steps will bereiterated.

For example, in one embodiment of a method for installing a masonryanchor system, a stud may be located at a position along the insulation.The word “stud” may generally refer to a stud driver and holder, athreaded stud, combinations thereof, or even an integral one-piece stud.The stud may be advanced into an inner structural supportive wall, whichmay or may not include a layer of insulation. The stud may be advancedsuch that a part of the stud that is capable of receiving the thermalclip attachment is left protruding from the inner structural supportivewall. This part of the stud may be a segment along the shank of the studor an outer driving head, for example. The thermal clip attachment maythen be affixed to the part. The thermal clip attachment may be rotatedto a horizontal position, and extensions of a wire tie may be insertedthrough holes in the thermal clip attachment. Another part of the wiretie may then be placed along a row of constituents forming an outermasonry veneer wall. Mortar or other cementitious material may be pastedonto the row of constituents and the wire tie as construction of theveneer wall continues.

It should be noted that various steps of this method may occur atdifferent points in time. For example, oftentimes the outer veneer wallis constructed long after the stud is advanced into the inner structuralsupportive wall. Thus, the steps involving the thermal clip attachmentand the wire tie may be performed long after various other steps.

Still another exemplary method of installing the masonry anchor unit mayinvolve preassembling the thermal clip attachment with the wire tie. Inparticular, the holes of the thermal clip attachment may receive theextensions of the wire tie before the wire nut attachment is affixed tothe stud driver and holder. Further, the extensions of the wire tie mayinclude a retaining feature, such as a kink or notch, for example, thatretains the thermal clip attachment on the extensions of the wire tie.The retaining feature may be positioned such that the thermal clipattachment may slide along a portion of the length of each extension.This capability may allow the wire tie to be adjusted up or downdepending on the point of attachment with the masonry wall. Oncepreassembled, the thermal clip attachment with the attached wire tie maybe pressed onto the head of the stud driver and holder. This embodimentwould thus eliminate the step of having to attach the wire tie to thethermal clip attachment after affixing the thermal clip attachment tothe stud driver and holder.

While the disclosure is susceptible to various modifications andalternative forms, specific exemplary embodiments thereof have beenshown by way of example in the drawings and have herein been describedin detail. It should be understood, however, that there is no intent tolimit the disclosure to the particular embodiments disclosed, but on thecontrary, the intention is to cover all modifications, equivalents, andalternatives falling within the scope of the disclosure as defined bythe appended claims.

What is claimed is:
 1. A masonry veneer anchor system comprising: a studcapable of being advanced into an inner structural supportive wall, thestud having a part that is intended to protrude from the innerstructural supportive wall after the stud is advanced; a thermal clipattachment capable of being attached to the stud after the stud isadvanced to the part of the stud that protrudes from the innerstructural supportive wall, the thermal clip attachment formed of acomposite material that acts as a thermal break between the stud and anouter masonry veneer wall; and a wire tie that can be attached to thethermal clip attachment and the outer masonry veneer wall.
 2. Themasonry veneer anchor system of claim 1 wherein said part of said studthat is intended to protrude from the inner structural supportive wallafter the stud is advanced contains an eye.
 3. The masonry veneer anchorsystem of claim 2 wherein said thermal clip attachment is configuredwith a peg to engage said eye of said stud.
 4. The masonry veneer anchorsystem of claim 3 wherein said thermal clip attachment is configuredwith two portions connected by at least one hinge wherein when saidportions are rotated around said hinge and closed together, said stud issecurely affixed to said thermal clip attachment.
 5. The masonry veneeranchor system of claim 1 wherein the wire tie further comprisesextensions and the thermal clip attachment further comprises holes forreceiving the extensions, wherein the extensions of the wire tie can beinserted through the holes of the thermal clip attachment.
 6. Themasonry veneer anchor system of claim 3 wherein the thermal clipattachment further comprises a cavity, wherein when the thermal clipattachment is closed, the peg occupies a portion of the cavity of thethermal clip attachment, and wherein when the eye of the stud is locatedover the peg before closure of the thermal clip attachment, the eye ofthe stud is secured within the cavity of the thermal clip attachment. 7.The masonry veneer anchor system of claim 3 wherein the thermal clipattachment has first and second portions that form a cavity forreceiving the eye of the stud, wherein the first and second portions arerotatable relative to one another and can be fastened to one anotherwith the eye of the stud secured within the cavity of the thermal clipattachment.
 8. A method of assembling a masonry veneer anchor system toan outer masonry veneer wall and an inner structural supportive wall,the method comprising the steps of: locating a stud at a position alongthe inner structural supportive wall; advancing the stud into the innerstructural supportive wall such that a part of the stud that receives athermal clip attachment remains protruding from the inner structuralsupportive wall; affixing the thermal clip attachment to the part of thestud that protrudes from the inner structural supportive wall; andattaching a wire tie to both the thermal clip attachment and the outermasonry veneer wall.